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How to dry out your Kawasaki 1100 exhaust system

Sounds pretty simple, you want to dry out the main expansion chamber and add cold water to the exhaust stinger for more RPM. I have compiled some diagrams and advice from a few members on here and took pictures along the way. My install was on my conversion Waveblaster with Kawasaki 1100, but I'm sure this will work for the SXR as well.

1.) I started with the 1/4" threaded hose barb install. Drill at about the 3:00 position (pipe upright) with Type "R" drill bit 11/32. Tap with the 1/8" NPT tap, install your hose barb.

2.) Next I tapped out the inside chamber (top of expansion chamber where stock water elbow was installed) You don't need to drill this out, just use the 8-32 tap and don't make it too big as the inner chamber wall is very thin. Install the 8/32" SS bolt with red threadlock and snug.

3.) Use 1/8" brass plug for upper threaded hole.

4.) Remove brass fitting in front of head pipe (1/4" line) I used a pair of vise grips and twisted a few times, came right out. Drill out this hole about 1/4" or so with Type "R" drill bit 11/32, tape with 1/8 NPT tap and install brass plug.

Re: How to dry out your Kawasaki 1100 exhaust system

Re: How to dry out your Kawasaki 1100 exhaust system

You will have to tap the stock manifold for dual cooling. My Blaster has a 1/2" line going to the stock position on the manifold, my boat came with dual cooling, the second line being a 3/8" line, which works out good for this install. I left the exhaust manifold installed on the engine and found a spot with good clearance from the starter and expansion chamber. I marked this spot blindly with a black Sharpie pen (see pics)

I removed the manifold and drilled out a 11/32" hole, then tapped with the 1/8" NPT Tap. Installed the 3/8" barbed elbow pointing back around the stock 1/2" fitting.

Next I slipped the manifold on the block and measured the water lines to the pump fittings and cut to size. Then I placed the expansion chamber on the manifold and measure out the spot for the 3/8" x 3/8" x 1/4" "T" fitting and cut the 3/8" incoming water hose to match.

Re: How to dry out your Kawasaki 1100 exhaust system

^^The picture above was sent to me by another member on here ^^

Kawasaki 9, I used the stock 1/2" elbow on the exhaust manifold and added a 3/8" elbow in the forward position (see pics) As far as water routing, I had a 3/8" and 1/2" water line coming from the pump. The 1/2" went straight to the manifold (stock routing) The 3/8" line has a "T" fitting right next to the exhaust stinger and a 1/4 line is run to the 1/4" threaded barb fitting. The line then keeps going to the manifold.

Also, don't forget to take the M5 x 0.8 pitch tap and tap out the inside of the 1/4" barbed fitting in the stinger. This allows the Mikuni jet installation in the top of the barb.